液压与气动维护分析解析

1、Maintenance Information Hydraulic and pneumatic systems 液压与气动维护说明1 Introduction 介绍The present operating instructions are intended to help the personnel responsible for service and maintenance work on the hydraulic and pneumatic control equipment to understand the way in which the individual control

2、loops function, to ensure the operating reliability of the control units, and to detect and eliminate quickly any potential weakpoints and causes of defects. 这个操作说明是为了操作人员了解关于液压和气动控制设备的检修和维护， 确保 控制单元可靠稳定的运行，并快速的发现和排除潜在的隐患。These instructions call for some technical knowledge and the ability to read h

3、ydraulic and pneumatic diagrams. 这些说明中的液压和气动简图需要有专业技能的人员读取。Schematic diagram 原理图The schematic diagram for the hydraulic and pneumatic control system comprises all control loops relevant to the plant, as well as the designations for necessary actuating of the solenoid valve to achieve certain functio

4、ns. In addition, the set values for pressure valves andmanometric switchesare provided. These schematic diagrams are thus an integral part of the present instructions.液压和气动控制系统的原理图包括所有相关的控制回路， 以及为了获得某些特定 功能所用的螺线管阀。另外，还包括压力阀的设定值和 manometric switches这 些原理图是液压和气动的维护说明必不可少的一部分。2 Safety notes安 全注意Due to

5、the immense forces and rapid movements that hydraulic and pneumatic cylinders and motors, respectively, can initiate in some cases, and the substantial initial tension of the pressure medium, appropriate care and technical knowledge must be applied when performing service work.由于液压和气动缸和电机在某些情况下会产生很大

6、的力和快速移动， 并当维修工 作开始时，压力工具的初次张紧、必须了解安全守则和技术知识。Some further general remarks are provided below: 下面提供了更多的一般性的注意事项：Before performing service work进行维修工作以前? Consult other specialists (mechanics, electricians) if necessary.如果必要咨询其他专家（机械专家、电气专家） 。? Lower or secure heavy loads to prevent them from making any

7、uncontrolled movements when the hydraulics or compressed air supply is switched off. 当液压或空压机供给关闭时，较低的或牢固的重载荷可以防止执行装置的失控。? Use safety equipment, such as lockable valves and switches, locking devices, etc. 使用安全设备，比如闸阀、开关和自锁装置等。? Lock the hydraulic pump by suitable means after switching off to prevent

8、it being switched on again.在关闭液压泵后通过适当方法锁住液压泵以防止其再次打开。? Close shut-off valves in the control loop concerned. 关闭控制回路截止阀。? Relieve pressure in oil and air pressure accumulators. 将油压和气压罐卸压。? Shut off operating and activity areas to prevent access by unathorised persons. 封闭操作和传动区域防止不知情况的人进入。During servi

9、ce work 在维修期间? Before detaching a pipe connection or unscrewing a valve, ensure that the system has been depressurised.Flexible hoses and pipes also have a similar effect to accumulators. 在拆卸管道或从阀门旋出螺丝以前，应确保装置已经卸压。 软管和管道也有类似的蓄能效果。? Before switching the hydraulic pump on again or opening shut-off val

10、ves, remember that this may lead to some machine parts being set in motion. 当再次打开液压泵或打开截止阀以前，记得这可能导致一些机械部件动作。? Ensure that there is no-one in the section of the plant concerned. 确保机械设备区域内无人。? Open shut-off valves slowly and listen to the sound of the flow. 慢慢打开截止阀然后听管道内流动的声音。? Hydraulic cylinders th

11、at have been emptied and pipes under low pressure must be filled with oil again and vented before actuating any switches to set a component in motion.在打开开关设置机构运动之前， 排空的液压缸和在低压以下的管道必须通过油孔 再次充满油。? If solenoid valves are shut down manually using the emergency switch, some logical in terlocks may be dis

12、abled. This can result in mach ine damage or pers onal injury.如果螺线管阀通过急停开关手动全关，一些逻辑自锁可能失效。这可能导致机器损坏或人身伤害。? Never tighten leaky screw fittings as long as the pipe is under pressure.如果管道在有压力的情况下，不要用有裂缝的螺丝拧紧设备。Handling of oil油的处理Remember that oil is easily in flammable and can be toxic un der certa in

13、circumsta nces. In additi on, oil should not be allowed to leak to the en vir onment.记住油很容易过热并且在某些环境下可能产生有毒物质。另外，有不应允许泄漏到环境中去。Therefore:? Keep suitable binding and ext in guish ing age nts at the ready.? Avoid skin con tact for any len gth of time.? Only dispose of used oil, used filter in serts and

14、 clea ning age nt polluted with oil at the disposal points provided for this purpose.因此：时刻配备隔离装置和灭火器。避免长时间皮肤接触。最好处理掉使用过的油，在处理这些油时要使用内置过滤器和清洁器防止油污 染。3 General guidelines总的指导方针3.1 Starting up hydraulic equipment打开液压设备Preparation Before start-up, perform the work described in Tab. 3-1.准备 打开设备之前，履行表3-1中

15、的描述。Procedure1Clean oil tank, (The oil tank must also be cleaned each time th色 oil is changed).2Check the hydraulic equipment. Check that the filter inserts are in good order.3Fill hydraulic oil in u$ing the ail service unit.Filtering: 10 microns absolute (or finer).AObserve the oil level at all tim

16、esfilling the tank.5Set pressure valves and variable displacement pumps to low pressure.6Close shut-off valves, open flaw control valves and throttles.步骤1清洁油罐（每次换油时，油罐必须清洁干净）。2检查液压设备。检查内置过滤器工作是否正常。3用加油装置填充液压油。 过滤：10微米（或澄清器）4当填充油罐时，要时刻注意油位。5设置压力阀和变量泵来降低压力。6关闭截止阀，打开流量控制阀和控油阀。InspectionsC on duct the f

17、ollowi ng checks accordi ng to Tab. 3-2: 检查根据下表3-2进行检查：Inspections1Are the cleaning hatches on the side of the oil tank properly sealed?2Is the electricall voltage for motors, solenoid valves. etc,r correct?3Check the gas pressure at the hydraulic accumulators CAUTION: Use only nitrogen when topping

18、 up!4Check correct direction of rotation by motor 日rd pump In jogging operation. The set direction of rotation is marked by an arrow on the pump casing.Tab. 3-2 Checks检杳1检查油罐开口侧的清洁并进行正确的密封。2校准电机、螺线管阀等的电压。3检查液压畜能器的气压值。 注意：只能使用氮气填充。4通过电机和泵的低速运转来检查校正旋转方 向。通过泵的保护壳上的箭头设定旋转方向。Flushing out the pipeg 中洗管道It

19、 is essential to blow air through the pipes from the hydraulic unit to the machine after assembly in order to remove any shav ings and dirt particles. In additi on, this can help in check ing whether the pipes lead to the correct con sumer.在组装完成后，在从液压装置到机器的管道进行必要的吹风，目的是为了移走所有的削片和灰尘。另外，这可以帮助检查管道管路是否正

20、确。Procedure1Disconnect the hydraulic pipes from lhe consumer and connect to one another.2Install temporary pipewodt to bypass the oontrol valves in order to tfansport tfie oil flowing back Irom the cofisumer point directly into fre tank3Fill the variable displacement pump with oil at the top leakage

21、 oil connection. Start up the pump一 If the pump does not prime ininiedialely,曲耳 suction pipe should be venled vim the measuring connection (directly at the pump).4Open the shut-off valves for the individual control units one aft)6r th韋 other and fill the plnt al low pressu悄-Sotne control units also

22、require (he directional control valves to be switched over fw this purpose.5X曲p a check on the oil 1 曲創 in ths tank.6Check pipework for leaksCheck the filler clogging 亦即lay7When the oil level in the tank does not drop any ftrther, the plant (each control loop j should be flushed out in this way for

23、approxiirulfily 1 hour.eSwilch off (he pump and connect the pipes up to the consumers again. Take care not to mix up the connections!Start the pump up again and fill the cylinder.g/ent ttie cylinder. Check the position of the piston during venting. ( can the air actually escape?)wAfter venting, scre

24、w on the safety c mps ag nin at the measuri rrg arid venti ng connecfton brandies.Tab. 3-3 Flushma CMjlthe aae亏步骤1从consumer拆下液压管道并连接到另一端。2安装临时管道来绕过控制阀目的是将回油从consumer point直接回到油罐。3在顶部的渗油连接用油填充变量泵。启动泵。如果泵不能立即准备好。吸油管口应有测量连接（直接在泵上）。4依次打开个别控制装置的截止阀并在低压情况下填充设备。一些 控制装置也需要方向控制阀来进行换向。5检杳油罐液位。6检查管道是否泄漏。检查过滤器是

25、否有堵塞情况。7当罐内液位不再下降时，设备（每个控制回路）应该用大量液体 冲洗大约1小时。8再将泵和consumer连接的管道关闭。当心不要分不清连接的管 路。再次启动泵并填满液压缸。9液压缸。检查在通气过程中活塞的位置。（检查是否漏气）10通风后，在测量和通风连接分支上安上安全防护罩。CAUTION 注意Special flushing instructions must be followed for control units with servo valves!See: Manu facturers docume ntati on.特殊的冲洗说明必须遵守带有补助阀门的控制装置。见：制造

26、商的说明书。Up to 80% of all faults at hydraulic systems are due to contamination of the hydraulic fluid.液压系统80%以上的故障是由液压油的污染引起的。We therefore recommend cleaning the hydraulic oil in the oil tank to the required oil clea nli ness accordi ng to ISO 4406 before start-up and after con duct ing any repairs usi

27、ng an oil service unit (bypass filter unit).因此我们在启动前和使用加油装置进行任何维修后(绕过过滤装置)必须按照ISO 4406清洁标准清洁油罐内的液压油。Test run Con duct the test run accord ing to the table Tab. 3-4.试运行按照表格3-4进行试运行。Procedure1Set the hydraulic pumps and pressure valves to operating pressure. Check the pipework system continusouly for

28、leaks whmn doing so.If there is a leak behveen the val /e and the connection plate, check the Sings. Ensure that the sealing surfaces are clean!2Set the components (throttle valves, flow control valves, pressure values, flow switches, etc) according to the diagram or functional description and the d

29、esired functron.The plant must be at operating temperature during setting.3The following temperatures must be checked dunng the running-in period:Operating oil (approx. 40 - 60aC)Electric motors and components4Oil level check5Keep a record of all setting data (pressures. movement times, temperatures

30、, etc.)6Update hydraulic diagrams.步骤1设置液压泵和溢流阀到运转压力。重复检查管道系统是否泄漏。 如果在阀门和法兰之间泄漏应检查 0型环。确保密封表面干净。2根据图表或功能描述和要求的功能设置元件（节流阀、流量控制阀、 压力阀和流量开关等）。在设置期间机械设备必须在操作温度。3在运行期间必须检查下面的温度：操作油（大约40-60C）电机和部件4油位检杳5记录所有设置数据（压力、运动时间和温度等）6更新液压图表DANGERNever tighten any leaky screw fittings that are under high pressure.Rel

31、ieve the pressure before tighte ning the screw fitt in gs!危险在高压的情况下，不要用有裂缝的螺丝拧紧设备。在拧紧螺丝之前应先降低压力。Starting up the pneumatic equipment开始运转气动设备InspectionsBefore start-up, perform the checks described in Tab. 3-1.检查在开始运转前，按表3-1执行检查工作。Procedure1Is the air network suitable for theequipments?(See compressed

32、 air specification for operating, instrument and blow air quality requirements!)2Have all structural elements been mounted and connected up correctly?3Is the electncal voltage for solenoid and proportional valves correct?4Are the dinectionF control valves in the correct starting position?步骤1检查空气系统是否

33、符合要求。（见空气压缩机操作说明书、仪表和空气质 量要求）2检查所有的结构部件是否已经安装和连接 止确。3校正电磁和比例阀的电压。4校正单向控制阀的开始位置。Preparation Before start-up, perform the work described in Tab. 3-2. 准备开始运转前，按表3-2进行工作。Procedure1Reduce flow control valves to mean value.2Set the pressure controller to low pressure.3Fill the pneumatic oiler with resin*f

34、ree spindle oil (viscosity 10-15mm2/sat50 C).Tab. 3-2 Preparation步骤1降低流量控制阀到中间值。2设置压力控制器到低压位置。3用油脂填充气动注油器（在50 时粘稠度为10-15 mm2/s）Test run Con duct the test run accord ing to the table Tab. 3-3. 试运行根据表3-3试运行。Procedure1Switch on compressed air supply.ADANGERSwitching on the compressed air supply may alr

35、eady set some machine components in motion.2Check the plant for leaks!3Start up the individual control loops one after the other and adjust the speeds and pressures to the operating conditio ns.4Set the pneumatic oiler to the lowest possible dosage.5The vent holes in the components must be protected

36、 to prevent dirt particles 自nd water from entering.6Flexiible hoses should not be pinched or buckled by the plant movements. This could cause faulty operation and premature wear7Make a record of all setting data and update the pneumatic diagrams.Pressure gauges 门步骤1打开压缩空气供给。危险警告在打开压缩空气供给可能导致一些机械部件动作

37、。2检查设备是否泄漏3依次打开单独的控制回路并调节转速和压力到运转状态。4设置气动注油器到最低供给量。5必须保护部件的排气孔以防灰尘和水进入。6设备移动时软管不应被夹住或扣紧。这可能导致运行故障和过早损 坏。7记下所有设置和更新气动图表。Pressure gauge压力计It is recommended to mark all setting pressures with an arrow or coloured line on the measuring device after start-up to facilitate routine checks. 在开机后推荐用箭头或在测量装置上

38、彩色线标记所有的设置压力以便检查。Directional control valves换向阀Directional control valves that are actuated electrically (solenoid valves) usually have a MANUAL EMERGENCY SWITCH. This allows the valve to be actuated manually if there is no control voltage. The MANUAL EMERGENCY SWITCH should only be used in emergenci

39、es or for test purposes. 电磁换向阀通常有一个“手动急停开关” 。如果没有控制电压，这个阀门可以进 行手动控制。急停开关只在紧急情况或测试时使用。CAUTION 注意When changing solenoids, look out for the control voltage!Take care not to mix up the plugs! 当改变电磁线圈时，检查控制电压！ 当心不要搞混插头电极。Maintenance and service in general 维护和检修概述Also read the safety instructions in item

40、2 of the present operating instructions. 安全说明在操作说明的第 2 项。Read the operation and maintenance instructions provided by the hydraulics supplier. 操作说明和维护说明由液压设备供应商提供。Regular, conscientious maintenance is essential to ensure trouble-free operation by the hydraulic and pneumatic plant.液压和气动的维护要符合规范并认真执行。M

41、aximum possible cleanliness is important in all maintenance and repair work. 所有维护和维修工作最重要的是清洁。The entire plant must undergo visual inspection every six months. Here the plant must be cleaned on the outside and checked for leaks, damage, corrosion and wear, as well as checking proper mounting of comp

42、onents and pipes.每六个月整体设备必须进行视觉检查。设备的外部必须清理干净并检查是否泄 漏、损坏、腐蚀和磨损，还要检查设备和管道的装配是否正确。During the start-up period the hydraulic fluid level should be checked daily, and then weekly after this period A shortage of hydraulic fluid can be an indication of concealed leakage points (look for the leak and repair

43、 it!). 在开机期间液压油的液位要每天检查， 然后每周液压油缺少时可能是隐藏的泄漏 点造成的(查找漏洞并进行修补) 。The first oil change should be carried out between 5,000 and 10,000 operating hours. 初次换油的运行时间在 5000小时到 10000 小时之间。Further oil changes should be determined together with the oil supplier after inspecting the oil.检查完油后加油工应坚决地进一步换油。We recomm

44、end the following hydraulic fluid for high-pressure hydraulics: 对于高液压我们推荐以下液压油：? Mineral oil according to DIN 51524, Part 2, with viscosity grade ISO VG46.根据 DIN 51524 第 2 段和粘稠度标准符合 ISO VG46 选择矿物油。At a steady-state temperature of 50C in the oil tank, we recommend the following hydraulic fluid type:油

45、罐内恒定油温应大于50C，我们推荐以下液压油类型：? Mineral oil according to DIN 51524, Part 2, with viscosity grade ISO VG68. 根据 DIN 51524 第 2 段和粘稠度标准符合 ISO VG68 选择矿物油。Required cleanliness according to ISO 4406 : 18/16/13 (corresponding approximately to the NAS 1638, Cat. 7, standard that is no longer valid) 根据 ISO 4406 :

46、18/16/13进行必要的清洁。(大约符合 NAS 1638, Cat. 7，没有明 确标准)In addition, the hydraulic fluid should have some water-absorbing capacity so that it can bind any condensation forming in the hydraulic system and carry it along. 另外，液压油应该有一定的吸水能力， 目的是它可以吸收液压系统和输送过程的 冷凝水。Ensure that the hydraulic filters are properly m

47、aintained. Contaminated hydraulic oil is one of the most common causes of damage. 液压油过滤器要进行适当保养。液压油污染是导致损坏的最普遍的原因之一。 Flexible hoses are wear parts subject to considerable aging depending on the form of installation and the operating conditions. Their service life is generally stated at 3-4 years! Re

48、place in good time!软管是易损部件， 它的老化速度很大程度上取决于装配质量和操作情况。 它们的 寿命一般在 3-4 年。要按时进行更换。Check operating pressures weekly! Frequent pressure setting changes are an indication of wear on the pressure valves. 每周检查运行压力。施压阀上压力的经常改变是磨损的迹象。Conduct maintenance on pneumatic oiler once a week and check oil level. 气动注油器要

49、每周维护依次并检查油位。Check hydraulic pumps and electric motors regularly to see whether they are running smoothly.检查液压泵和电机，看它们是否运行平稳。Loud noises at the pump may indicate that air is being sucked in. 泵的噪音大可能是吸入空气的迹象。Depending on the operation conditions, the hydraulic and pneumatic components should be overha

50、uled after 2-3 years.根据运行状况，液压和气动部件应 2-3 年大修一次。Stock of spare parts备件的储备It is recommended to keep a well-considered stock of the main spare parts. 主要部件要保持有一个完好的备件。Based on economic factors, the following should be applied: 基于经济效益因素，应考虑以下建议：Stock only complete components, such as pumps, directional c

51、ontrol valves, pressure valves, etc., that can be replaced as a complete unit in the event of damage! 备品是完整的部件，像泵、换向阀和压力阀等。一旦损害可以整体更换。It has not provided valuable to stock individual parts, such as washers, nozzles, valve springs, diaphragms, etc. or it has at least proved difficult to handle. 不提供或提

52、供数量很难满足要求的个别关键部件的备品。 像洗涤器、 喷嘴、阀门 弹簧和隔膜等。? Suppliers demand a minimum number or minimum order value for small parts. 对于小部件供应商提供最少的数量或最少的订单。? Rubber components, such as diaphragms, seals, and also flexible hoses, have a limited service life (temperature, humidity, light, chemicals).橡胶部件像隔膜、 密封还有软管有有限的

53、使用寿命 (温度、湿度、光线和化学品)。In this connection we would like to point out that ANDRITZ AG does not perform repairs to hydraulic or pneumatic equipment itself! 液压或气动设备不能自己修理，应联系 ANDRITZ AG 指出问题。We can, however, forward any faulty equipment to the manufacturer unless you prefer to do this directly or to commi

54、ssion a service workshop to carry out the repair. The decision as to whether it is more economical to repair or replace the component is then up to the party commissioned with the repair. 不管怎样，我们可以将任何有故障的设备进行返厂修理除非你宁愿自己修理或委 托一个机修车间去修理它们。这取决于部件的维修费用是否更节省。Selection criteria for spare part略件的选择标准Spare

55、parts for hydraulic and pneumatic controls can be classified in 3 groups according to their importance: 液压和气动部件根据它们的重要程度可分为 3 等：Spare parts of prime urgency 1 最重要的备件“ 1”This category contains wear parts and the most urgent spare parts. 这个类别包括易损部件和最重要的部件。If any of these parts are missing or faulty, t

56、his could cause a longer machine shutdown period.如果这些部件缺少或损害，这将导致机器长时间停机。Recommendation: Keep parts in stock 推荐：保持一直有备件Examples:? Filter elements for hydraulic filter? Spare solenoids for directional control valves? Proportional valves, servo valves? Special equipment,? Measuring transducers, electr

57、onic parts例如：液压过滤器的滤芯 换向阀的备用电磁线圈 比例阀和 servo 阀 特别设备 测量传感器、电力部件Spare parts of secondary urgency 2 次重要备件“ 2”This category comprises spare parts that are normally required to guarantee continuous operation.该种类部件通常保证连续运转。These parts provide normal protection. 这些部件提供正常的保护。 Recommendation: Keep parts in st

58、ock 推荐：保持一直有备件Examples:? Directional control valves? Pressure valves, filter regulators, boosters ? Pressure switches ? Flow control units, pressure-compensated throttles? Pressure gauges for control panels? Heat exchangers? Flexible hoses? Pumps, couplings, motors (each hydraulic unit is already fi

59、tted withspare pumps). 例如：换向阀 压力阀、过滤器、助推器 压力开关流量控制装置、压力补偿控制阀 压力计控制面板热交换器软管泵、联轴器、电机(每个液压装置都装有抽吸泵)Spare parts of tertiary urgency 3 第 3 重要的备件“ 3”These spare parts afford maximum protection for continuous operation. 这些部件提供连续生产的最大保护。Shutdown times can be reduced to a minimum. 停机次数降低到最小。The customer deci

60、des whether to keep a stock of these parts or not. 客户决定是否保持这部分备件。Examples:? Level switches? Throttle valves, one-way restrictors,? Shut-off valves? (subordinated) Pressure gauges? Non-return valves, shuttle valves? Quick-acting ventilation valves例如：限位开关节流阀、单向限流器截止阀(次要的)压力计单行程阀、双行程阀快速空气流通阀ANDRITZ AG